Candy Manufacturing Support Pallet and Method of Use

ABSTRACT

A manufacturing support pallet includes a support with a substantially planar support surface, and a plurality of rails oriented substantially normal to the support surface and positioned adjacent to the support. The support surface defines a plurality of holding slots where each holding slot is sized substantially identically and configured to receive a manufactured product package. The product package can be a candy cane tray. A method for manufacturing boxes includes producing a consumer product, such as a candy cane tray, aligning one or more of the consumer products in a point of sale insert, and placing the point of sale insert into a holding slot that is located on a support pallet. A manufacturing system includes a support tray defining a plurality of receiving areas configured to receive a manufactured product package, a plurality of support rails, and a transport tray configured to receive a plurality of support trays and a plurality of support rails.

INTRODUCTION

Some candies such as candy canes are seasonal with a bigger demand over the winter holidays. Many of those candies have shelf lives that are longer than a few months. Thus, the candies can be manufactured many months before they are shipped to be sold to consumers. Moreover, it may be advantageous or even required to manufacture candy canes year round due to economics and production limits.

Candy canes are fragile and have an odd shape that can be difficult to support. Manufacturing candy canes well before they are sold requires storage space and special supports that protects the candy canes but also allows for easy loading when the boxes are ready. Thus, a suitable support and storage system that is low cost, light weight, and minimizes space used is desirable.

The packaging for the candies may not be ready until just before the season begins. For instance, the design of a display on a box might be finalized weeks before the candies are shipped. However, a few weeks might not be enough time to manufacture all the candy to meet expected consumer demand. It is with respect to this general tension that the embodiments of the present application are directed.

SUMMARY

In summary, the present disclosure relates to a manufacturing support system that includes supporting, storing and displaying candy canes.

The manufacturing support system can include a support pallet that has a planar surface that defines a plurality of holding slots, where each holding slot is sized to receive and support a manufacturing insert tray. The support system can also include support rails that are positioned adjacent to the surface or that are connected to the surface. The holding slots may be rectangular and arranged such that the holding slots form a column on the support surface. More than one support pallet can be combined for use and be placed on a supporting carrier.

A method for manufacturing boxes is also disclosed. The method can include producing a consumer product, such as a candy cane, and placing the product in an insert tray. Then the tray can be positioned in a holding slot of a support pallet. The support pallet can then be stored in a location for days, weeks or months until the insert trays are removed and a display box is positioned over or around the insert tray. Multiple support pallets can be placed on a carrier, along with support rails, to facilitate moving and storing. The support pallet can also be used in a point-of-sale display.

These and various other features as well as advantages which characterize the systems and methods described herein will be apparent from a reading of the following detailed description and a review of the associated drawings. Additional features are set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the technology. The benefits and features of the technology will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The following figures, which form a part of this application, are illustrative of described technology and are not meant to limit the scope of the claims in any manner, which scope shall be based on the claims appended hereto.

Referring now to the drawings, wherein like reference letters and numerals indicate corresponding structure throughout the several views:

FIG. 1 is a perspective view of a manufacturing support pallet according to a first example embodiment of the present disclosure;

FIG. 2 is a front view of a manufacturing support pallet according to a first example embodiment of the present disclosure;

FIG. 3 is a top view of a manufacturing support pallet according to a first example embodiment of the present disclosure;

FIG. 4 is a top view of a manufacturing support pallet according to a second example embodiment of the present disclosure;

FIG. 5 is a top view of a carrier with manufacturing support pallets according to the first example embodiment;

FIG. 6 is a top view of a carrier supporting manufacturing support pallets according to the second example embodiment;

FIG. 7 is a top front view of a manufacturing support pallet with an example candy product according to an example embodiment of the present disclosure;

FIG. 8 is a perspective view of a manufacturing support pallet with an example candy product according to an example embodiment of the present disclosure;

FIG. 9 is a block diagram illustrating a method of manufacturing a candy product package according to an example embodiment of the present disclosure;

FIG. 10 is a perspective view of a box loaded with candy canes according to the principles of the present invention; and

FIG. 11 a perspective view of an insert loaded with candy canes.

DETAILED DESCRIPTION

As briefly described above, embodiments of the present invention are directed to a candy product manufacturing support system, as well as a method for its use. In general, the system described herein includes a manufacturing support pallet that provides a holding structure to store candy products such as candy canes before the packaging is finalized. Although used between the manufacture of the product and the finalization of the packaging, it is within the scope of this disclosure to additionally use the support pallet during shipping and/or display of the finalized product.

As mentioned above, candy canes are generally brittle, easily broken and awkwardly shaped for storage and handling purposes. The use of the support pallet can enable the production of the candy canes at a convenient time based on the manufacturer's preferences and availability. In some circumstances, the manufactured candy canes can sit on the support pallet for weeks, months or longer before being placed into a finalized package.

In accordance with the present disclosure, an example manufacturing support pallet 100 is illustrated in FIGS. 1-3. As illustrated, the manufacturing support pallet 100 includes a support panel 102 with base surface 104 and holding slots 106, as well as support rails 108 connected to support panel 102 along seam 110. The manufacturing support pallet 100 can be stacked on top of other support pallets and/or arranged alongside other manufacturing support pallets 100, as shown and described in more detail below with reference to FIG. 5. Other embodiments can include more or fewer components.

The manufacturing support pallet 100 can be made of any suitable material, such as corrugated cardboard, plywood, wood, aluminum, balsa wood, a plastic, etc. In embodiments, the support panel 102 and support rails 108 are typically made of the same material.

Example base surface 104 is substantially planar and is depicted as being oriented substantially parallel to the ground. In other embodiments, base surface 104 can be angled relative to the ground, for example, at an angle of between about 1° to about 60°. The base surface 104 can have varying thickness in different embodiments to provide the structure and support necessary to hold the product packages.

The example manufacturing support pallet 100 is shown with the base surface 104 positioned at approximately the bottom quarter of the support rails 108. The distance of the base surface 104 to the bottom of the support rails 108 is shown in FIG. 1 as height H. The manufacturing support pallet 100 can be designed with the base surface 104 positioned at a height H such that it accommodates the shape and size of the product package. In an embodiment of the example, the manufacturing support pallet 100 has a base surface 104 that is not fixed but is height-adjustable.

The base surface 104 defines one or more holding slots 106. The holding slots 106 can be rectangular, as shown in the example. Alternatively, the holding slots 106 can have different cross-sectional shapes to accommodate differently sized product packages, such as square, circle, trapezoid, parallelogram, etc. As shown in FIG. 3, in some embodiments the holding slots 106 are aligned such that the centroids of the holding slots are linear.

In the embodiment shown, each holding slot 106 is congruent to the one or more other holding slots 106 defined by the base surface 104. In other embodiments, the base surface 104 can define holding slots 106 with different shapes. The spacing between adjacent edges of the holding slots 106 can vary, for example, from about 0.25 inch to about 3 inches; with typical spacing being about 0.5 inch; about 0.75 inch; about 1 inch; about 1.25 inches; about 1.5 inches; about 2 inches; and about 2.5 inches.

The holding slots 106 can be arranged in a row along the length of the base surface 104, as shown in FIG. 3. In a different embodiment of the example, the holding slots 106 can be rotated about 90° to be arranged in a row along the width of the base surface 104.

As shown in the example in FIG. 3, a space L is disposed between the outer edges of the holding slots 106 and the inner surface of support rails 108. In other embodiments, the space L is more or less than that shown in FIG. 3.

The example support panel 102 can be joined to each support rail 108 at seam 110. In embodiments shown of FIG. 3, the two support rails 108 and the support panel 102 are separate pieces, for example, three pieces of corrugated cardboard. In those embodiments, the support panel 102 can be affixed to the support rails 108 using methods known in the art, for example, using an adhesive or fastener. In other embodiments, the support rails 108 and support panel 102 are made from one continuous piece.

The support rails 108 can also include one or more receiving cavities configured to receive and hold extensions from the support panel 102. In that embodiment, the rails 108 can include receiving cavities at different heights H such that the support panel 102 can be positioned at different heights. For example, the extensions on support panel 102 can include a knob or other shape on the end. The receiving cavity on the support rail 108 can include a first portion sized to allow the knob or other shape to pass through and a narrower portion such that the extension can “snap” into place.

In accordance with the present disclosure, an example manufacturing support pallet 200 is illustrated in FIG. 4 according to a second embodiment. As illustrated, the manufacturing support pallet 200 includes a support panel 202 with base surface 204 and holding slots 206, as well as support rails 208. Other embodiments can include more or fewer components.

The manufacturing support pallet 200 can be made of any suitable material, such as corrugated cardboard, plywood, wood, aluminum, balsa wood, a plastic, etc. In embodiments, the support panel 202 and support rails 208 are made of the same material.

The support panel 202 can stand on a surface without the help of support rails 208. The support panel 202 can include rails that run lengthwise, widthwise, or both. The support panel 202 may also include four leg portions extending normal to the base surface 204. The support panel 202 has an adjustable height. In other embodiments, the support panel 202 has a fixed height but different embodiments can have different heights.

Example base surface 204 is substantially planar and is depicted as being oriented substantially parallel to the ground. In other embodiments, base surface 204 can be angled relative to the ground, for example, at an angle of between about 1° to about 60°. The base surface 204 can have varying thickness in different embodiments to provide the structure and support necessary to hold the product packages.

The base surface 204 defines one or more holding slots 206. The holding slots 206 can be rectangular, as shown in the example. Alternatively, the holding slots 206 can have different cross-sectional shapes to accommodate differently sized/shaped product packages, such as square, circle, trapezoid, parallelogram, etc. In the embodiment shown, each holding slot 206 is congruent to the one or more other holding slots 206 defined by the base surface 204. In other embodiments, the base surface 204 can define holding slots 206 with different shapes. The spacing between adjacent edges of the holding slots 206 can vary, for example, from about 0.25 inch to about 3 inches; with typical spacing being about 0.5 inch; about 0.75 inch; about 1 inch; about 1.25 inches; about 1.5 inches; about 2 inches; and about 2.5 inches

The holding slots 206 can be arranged in a row along the length of the base surface 104, as shown in FIG. 3. In a different embodiment, the holding slots 206 can be rotated about 90° to be arranged in a row along the width of the base surface 104.

The support rails 208 can be u-shaped, similar to rails 108. In other embodiments, support rails 208 are planar or substantially planar.

As shown in the example in FIG. 3, a space W is between the outer edges of the holding slots 106 and the outer edge of panel 202. In other embodiments, the space W is greater or less than that shown in FIG. 3.

In contrast to the example embodiment shown in FIGS. 1-3, the example support pallet 200 has support rails 208 that are not connected to the panel 202. Each support rail 208 can move independently from the panel 202 and, likewise, panel 202 can move independently from the rails 208.

FIG. 5 illustrates an example embodiment of storage system 250. The storage system 250 can also be used as an in-store display for the finished product packages. As shown in FIG. 5, the example storage system 250 includes a carrier 260 and a plurality of manufacturing support pallets 100. Other embodiments can include more or fewer components.

The embodiment shown in FIG. 5 includes three manufacturing support pallets 100 arranged side-by-side. However, the example embodiment carrier 260 can be sized to support any number of manufacturing support pallets 100. For example, carrier 260 can be sized to support two, three, four, five, six, seven or eight, or more, manufacturing support pallets 100 side by side. Additionally, carrier 260 can be sized to support multiple columns of manufacturing support pallets 100, for example, two columns each with three manufacturing support pallets 100 side by side.

The carrier 260 can be made of any suitable material, such as corrugated cardboard, plywood, wood, aluminum, balsa wood, a plastic, etc. In embodiments, the carrier 260 can have raised edges.

As shown in FIG. 5, the manufacturing support pallets 100 can be arranged in the carrier 260 such that there is space between each of the pallets 100 and the edges of the carrier 260. In other example embodiments, the carrier 260 is sized such that the manufacturing support pallets 100 fit flush or snug to the edges of the carrier 260, thereby substantially restricting any lateral movement of the manufacturing support pallets 100.

One or more carriers 260 can be stacked on top of each other. In embodiments, rails 108 can provide support for the carrier 260 placed above.

FIG. 6 illustrates an example embodiment of storage system 270. The storage system 270 can also be used to as an in-store display for the product packages. As shown in FIG. 6, the example storage system 270 includes a carrier 280 and a plurality of manufacturing support pallets 200. Other embodiments can include more or fewer components.

The embodiment shown in FIG. 6 includes three manufacturing support pallets 200 arranged side-by-side. However, the carrier 280 can be sized to support any number of manufacturing support pallets 200. For example, carrier 280 can be sized to support two, three, four, five, six, seven or eight, or more, manufacturing support pallets 200 side by side. Additionally, carrier 280 can be sized to support multiple columns of manufacturing support pallets 200, for example, two columns each with three manufacturing support pallets 200 side by side.

The carrier 280 can be made of any suitable material, such as corrugated cardboard, plywood, wood, aluminum, balsa wood, a plastic, etc. In embodiments, the carrier 280 has raised edges or another structure designed to limit lateral movement of the support pallets 200.

As shown in FIG. 6, the manufacturing support pallets 200 can be arranged in the carrier 280 such that there is space between each of the pallets 200 and the edges of the carrier 280. In other example embodiments, the carrier 280 is sized such that the manufacturing support pallets 200 fit flush or snug to the edges of the carrier 280, thereby substantially restricting lateral movement of the manufacturing support pallets 200.

One or more carriers 280 can be stacked on top of each other. In some embodiments, rails 208 can provide support for the carrier 280 placed above. As discussed above with reference to FIG. 4, rails 208 are not connected to panel 202 in manufacturing support pallet 200. Thus, when multiple carriers 280 are stacked, a panel 202 can be removed from a carrier 280 without needing to remove the entire carrier 280 from the stack of carriers.

Referring now to FIGS. 7 and 8, an example manufacturing support pallet 300 is shown with an example product. As shown, the example manufacturing support pallet 300 includes a support panel 302 with base surface 304 and holding slots 306, and support rails 308 connected to the support panel 302 at seam 310. Other embodiments can include more or fewer components.

As shown, the example manufacturing support pallet 300 includes three separate cardboard pieces. Similar to the second example embodiment 200 shown in FIG. 4, the two support rails 308 are not connected to the panel 304. However, in other embodiments not shown, the support rails are connected to the support panel 302 in manner similar to example embodiment 100 discussed above with reference to FIGS. 1-3. Also, as shown, the support rails 308 have a substantially upside-down “U” shaped cross section. In other embodiments of the example, the support rails can have a “closed” cross section that is substantially rectangular in shape.

The example manufacturing support pallet 300 is shown supporting two example product packages 400. The example product packages 400 are candy cane insert trays that can be placed inside an outer display package as described in U.S. Patent Application 6______, the entirety of which is hereby incorporated by reference.

FIG. 10 shows a packaging system 20 configured for packaging candy and in particular for packaging and displaying candy canes 10. The packaging system 20 includes a box 22 and insert 24 for supporting the candy canes 10 and configured to insert into the box 22. As shown in FIGS. 10 and 11, an insert 24 is configured to support and retain the candy canes 10. The candy canes 10 are supported with the elongate section 12 retained in the space formed between the first and second cross pieces 62, 64 and the back 52. The hook section 14 passes over and around the top of the first cross piece 62 and the hook ends 16 extend downward over the front of the first cross piece 62. Moreover, the bottom 60 extends forward beyond the sides 56 and the front formed by the cross pieces 62 and 64. The bottom 60 can serve as a spacer when the insert 24 is placed in a box 22.

With the configuration shown, it can be appreciated that the candy canes 10 may be stored in the insert 24 and do not immediately need to be placed in a box 22. Therefore, production may continue throughout the year and changes may be made to update graphics and other information on the box after the candy canes 10 are produced and stored in the insert 24. Moreover, versions of the box 22 having different graphics may be utilized with the same insert 24 and candy canes 10. It will also be appreciated that although the insert 24 and box 22 shown in FIGS. 10 and 11 are configured for holding twelve candy canes 10, fewer or larger numbers of candy canes may be utilized with a narrower or wider insert 24 and box 22.

Although the example manufacturing support pallet 300 is shown with only two holding slots 306, it is within the scope of this disclosure that the base surface 304 defines many more than two slots 306 as discussed above with reference to FIG. 4. Further, the disclosure is not limited to supporting candy cane trays—any type of product package can be placed within the holding slots 306.

FIG. 9 is a block diagram of an example method 500 for using an example manufacturing support pallet 100 or 300. The example method 500 includes manufacturing product (step 505), manufacturing a product package (step 510), placing the product in the product package (step 515), positioning the product package in an example support pallet (step 520), arranging a support pallet in a carrier (step 525), and removing the product package from the support pallet (step 530). Other embodiments can include more or fewer steps.

The method 500 begins with manufacturing a product (step 505) and manufacturing a product package (step 510). The product can be a confectionary product such as candy. In other embodiments, the product can be any product that is placed in a package, including packages with display overlays. The product (step 505) and product package (step 510) do not need to be manufactured simultaneously.

After the product and product package are manufactured (steps 505 and 510), the product is placed in the product package (step 515). In one or more embodiments, step 515 can be performed by hand or automatically.

When the product has been arranged in the product package (step 515), the next step in example method 500 is to position the product package in the support pallet (step 520). At this point in the example method 500, the support pallet and the product packages can be stored for later retrieval.

One or more support pallets can then be arranged in a carrier (step 525). Example arrangements of support pallets in a carrier are shown and described in more detail above with reference to FIGS. 5 and 6. One or more carriers can be stacked on top of each other. The one or more carriers with support pallets can next be stored or used for a consumer display.

The product package is next removed from the support pallet (step 530). The product package is removed hours, days, weeks, months or longer after it is arranged in the support pallet in the carrier (step 525). A cover or display wrapping can be added to the product package after removal (step 530). Then, the product package, with the cover or display wrapping, can be placed back in the support pallet, which can then go in the carrier. The carrier with the covered or wrapped product packages can then be used in shipping and/or a point-of-sale display.

As used herein, “about” refers to a degree of deviation based on experimental error typical for the particular property identified. The latitude provided the term “about” will depend on the specific context and particular property and can be readily discerned by those skilled in the art. The term “about” is not intended to either expand or limit the degree of equivalents which may otherwise be afforded a particular value. Further, unless otherwise stated, the term “about” shall expressly include “exactly,” consistent with the discussions regarding ranges and numerical data. Concentrations, amounts, and other numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 4 percent to about 7 percent” should be interpreted to include not only the explicitly recited values of about 4 percent to about 7 percent, but also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 4.5, 5.25 and 6 and sub-ranges such as from 4-5, from 5-7, and from 5.5-6.5; etc. This same principle applies to ranges reciting only one numerical value. Furthermore, such an interpretation should apply regardless of the breadth of the range or the characteristics being described.

The description and illustration of one or more embodiments provided in this application are not intended to limit or restrict the scope of the invention as claimed in any way. The embodiments, examples, and details provided in this application are considered sufficient to convey possession and enable others to make and use the best mode of claimed invention. The claimed invention should not be construed as being limited to any embodiment, example, or detail provided in this application. Regardless whether shown and described in combination or separately, the various features (both structural and methodological) are intended to be selectively included or omitted to produce an embodiment with a particular set of features. Having been provided with the description and illustration of the present application, one skilled in the art may envision variations, modifications, and alternate embodiments falling within the spirit of the broader aspects of the claimed invention and the general inventive concept embodied in this application that do not depart from the broader scope. 

1. A manufacturing support pallet, comprising: a support with a substantially planar support surface; wherein the support surface defines a plurality of holding slots, each holding slot being sized substantially identically and configured to receive a manufactured product package; and a plurality of rails oriented substantially normal to the support surface and positioned substantially adjacent to the support.
 2. The manufacturing support pallet of claim 1, wherein the holding slots are arranged such that the holding slots form a column.
 3. The manufacturing support pallet of claim 1, wherein the holding slots are substantially rectangular.
 4. The manufacturing support pallet of claim 1, wherein the plurality of rails are connected to the support.
 5. The manufacturing support pallet of claim 4, wherein the holding slots are aligned such that centroids of the rectangular holding slots in the column are linear.
 6. The manufacturing support pallet of claim 1, wherein the holding slots are arranged such that the holding slots form a column; and wherein the manufacturing support pallet includes multiple supports to form a pallet with multiple columns of holding slots.
 7. The manufacturing support pallet of claim 1, wherein the rails are connected to the support; wherein the holding slots are substantially rectangular; and wherein adjacent edges of the rectangular holding slots are spaced less than 2 inches apart.
 8. A method for manufacturing boxes, comprising: producing a consumer product; aligning one or more of the consumer product in a point of sale insert; placing the point of sale insert in a holding slot, the holding slot located on a support pallet.
 9. The method of claim 8, further comprising: removing the point of sale insert; and positioning a display over the point of sale box.
 10. The method of claim 9, wherein the consumer product is candy cane;
 11. The method of claim 9, further comprising placing the support pallet in a storage location.
 12. The method of claim 8, further comprising placing the support pallet in a carrier and storing the carrier.
 13. The method of claim 12, further comprising removing the carrier from storage; and using the carrier in a point-of-sale display.
 14. A manufacturing system, comprising: a support tray defining a plurality of receiving areas configured to receive a manufactured product package; a plurality of support rails; and a transport tray configured to receive a plurality of support trays and a plurality of support rails.
 15. The manufacturing system of claim 14, wherein the manufactured product package is a candy cane package.
 16. The manufacturing system of claim 14, wherein the receiving areas are substantially rectangular.
 17. The manufacturing system of claim 16, wherein the plurality of support trays are arranged in one column in the transport tray.
 18. The manufacturing system of claim 16, wherein the plurality of support trays are arranged in the transport tray with a plurality of rows and a plurality of columns of support trays.
 19. The manufacturing system of claim 17, wherein a plurality of transport trays are stacked on top of each other.
 20. The manufacturing system of claim 19, wherein the stack of transport trays is used in a consumer point-of-sale display. 